Air data probe with enhanced conduction integrated heater bore and features

ABSTRACT

A probe head of an air data probe includes a body extending from a first end to a second end of the probe head and a rod heater. The body includes an inlet adjacent the first end of the probe head, an air passageway extending through the body from the inlet to a second end of the probe head, a water dam extending radially through the body such that the air passageway is redirected around the water dam, a heater bore extending within the body, and an enhanced conduction area between heater bore and an exterior surface of the probe head. The inlet, the air passageway, the water dam, and the heater bore are all unitary to the body. The rod heater is positioned within the heater bore.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is related to U.S. application Ser. No. ______,entitled AIR DATA PROBE WITH INTEGRATED HEATER BORE AND FEATURES, filedconcurrently, and having Attorney Docket No. 131994US01-U200-012291,which is incorporated by reference in its entirety.

BACKGROUND

The present disclosure relates generally to air data probes, and inparticular, to heaters for air data probes.

Air data probes are installed on aircraft to measure air dataparameters. Air data parameters may include barometric static pressure,altitude, air speed, angle of attack, angle of sideslip, temperature,total air temperature, relative humidity, and/or any other parameter ofinterest. Examples of air data probes include pitot probes, total airtemperature probes, or angle of attack sensors.

Air data probes are mounted to an exterior of an aircraft in order togain exposure to external airflow. Thus, air data probes are exposed tothe environmental conditions exterior to the aircraft, which are oftencold. As such, heaters are positioned within air data probes to ensurethe air data probes function properly in liquid water, ice crystal, andmixed phase icing conditions. It can be difficult to successfullyarrange the heater within the air data probe.

SUMMARY

A probe head of an air data probe includes a body extending from a firstend to a second end of the probe head and a rod heater. The bodyincludes an inlet adjacent the first end of the probe head, an airpassageway extending through the body from the inlet to a second end ofthe probe head, a water dam extending radially through the body suchthat the air passageway is redirected around the water dam, a heaterbore extending within the body, and an enhanced conduction area betweenheater bore and an exterior surface of the probe head. The inlet, theair passageway, the water dam, and the heater bore are all unitary tothe body. The rod heater is positioned within the heater bore.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an air data probe.

FIG. 2A is a partial perspective view of a probe head of the air dataprobe.

FIG. 2B is a cut away view of a probe head of the air data probe.

FIG. 2C is a cross-sectional view of the probe head of the air dataprobe.

FIG. 2D is a cross-sectional view of the probe head of the air dataprobe.

FIG. 2E is a cross-sectional view of the probe head of the air dataprobe.

FIG. 2F is a front view of the probe head of the air data probe.

FIG. 3A is a partial perspective view of a second embodiment of a probehead.

FIG. 3B is a cut away view of a second embodiment of the probe head.

FIG. 3C is a cross-sectional view of the second embodiment of the probehead.

FIG. 3D is a cross-sectional view of the second embodiment of the probehead.

FIG. 3E is an end view of the second embodiment of the probe head.

FIG. 4A is a perspective top view of the air data probe showing enhancedconduction areas of a third embodiment of the probe head.

FIG. 4B is a partial perspective front view of the third embodiment ofthe probe head showing the enhanced conduction areas.

FIG. 4C is a partial perspective front view of the third embodiment ofthe probe head with part of the body of the probe head removed to showthe enhanced conduction areas.

FIG. 4D is a cross-sectional view of the third embodiment of the probehead taken along line D-D of FIG. 4A.

FIG. 4E is a cross-sectional view of the third embodiment of the probehead taken along line E-E of FIG. 4A.

FIG. 5A is a perspective top view of the air data probe showing anenhanced conduction area of the fourth embodiment of the probe head.

FIG. 5B is a partial perspective front view of the fourth embodiment ofthe probe head showing the enhanced conduction area.

FIG. 5C is a partial perspective front view of the fourth embodiment ofthe probe head with part of the body of the probe head removed to showthe enhanced conduction area.

FIG. 5D is a cross-sectional view of the fourth embodiment of the probehead taken along line D-D of FIG. 5A.

FIG. 5E is a cross-sectional view of the fourth embodiment of the probehead taken along line E-E of FIG. 5A.

DETAILED DESCRIPTION

In general, the present disclosure describes an air data probe with aprobe head that has an additively manufactured body including unitarywater dams, air passageways, and one or more heater bores for a rodheater or heaters, resulting in simplified assembly, enhancedrepeatability, and efficient heat distribution. The probe head may alsoinclude one or more enhanced conduction areas between or extending fromone or more heater bores and an exterior surface of the body to increaseand further tailor the heat distribution.

FIG. 1 is a perspective view of air data probe 10. Air data probe 10includes probe head 12, strut 14, and mounting flange 16. Probe head 12includes first end 18 and second end 20.

Air data probe 10 may be a pitot probe, a pitot-static probe, or anyother suitable air data probe. Probe head 12 is the sensing head of airdata probe 10. Probe head 12 is a forward portion of air data probe 10.Probe head 12 has one or more ports positioned in probe head 12.Internal components of air data probe 10 are located within probe head12. Probe head 12 is connected to a first end of strut 14. Strut 14 isblade-shaped. Internal components of air data probe 10 are locatedwithin strut 14. Strut 14 is adjacent mounting flange 16. A second endof strut 14 is connected to mounting flange 16. Mounting flange 16 makesup a mount of air data probe 10. Mounting flange 16 is connectable to anaircraft.

Probe head 12 has first end 18 at one end, or an upstream end, andsecond end 20 at an opposite end, or a downstream end. First end 18 ofprobe head 12 makes up a tip of probe head 12. Second end 20 of probehead 12 is connected to strut 14.

Air data probe 10 is configured to be installed on an aircraft. Air dataprobe 10 may be mounted to a fuselage of the aircraft via mountingflange 16 and fasteners, such as screws or bolts. Strut 14 holds probehead 12 away from the fuselage of the aircraft to expose probe head 12to external airflow. Probe head 12 takes in air from surroundingexternal airflow and communicates air pressures pneumatically throughinternal components and passages of probe head 12 and strut 14. Pressuremeasurements are communicated to a flight computer and can be used togenerate air data parameters related to the aircraft flight condition.

FIG. 2A is a partial perspective view of probe head 12 of air data probe10. FIG. 2B is a cut away view of probe head 12 of air data probe 10.FIG. 2C is a cross-sectional view of probe head 12 of air data probe 10.FIG. 2D is a cross-sectional view of probe head 12 of air data probe 10.FIG. 2E is a cross-sectional view of probe head 12 of air data probe 10.FIG. 2F is a front view of probe head 12 of air data probe 10. FIGS. 2A,2B, 2C, 2D, 2E, and 2F will be discussed together. Air data probe 10includes probe head 12. Probe head 12 includes first end 18, second end20, body 22, and heater 24. Body 22 includes exterior surface 26, inlets28A, 28B, 28C, and 28D, air passageways 30A, 30B, 30C, and 30D, waterdams 32A and 32B, and heater bore 34. Heater bore 34 includes interiorsurface 36.

Probe head 12 has first end 18 making up the tip of probe head 12.Second end 20 is opposite first end 18. Second end 20 of probe head 12is connected to strut 14 (shown in FIG. 1 ). Body 22 of probe head 12extends from first end 18 to second end 20. Body 22 is a unitary, orsingle-piece, structure. Body 22 is additively manufactured and made ofnickel or any other suitable material. Heater 24 is positioned withinbody 22. In this embodiment, a single heater 24 extends through acenter, or down the middle, of body 22. Heater 24 is a rod heater, whichincludes both rod and rod-like structures. Heater 24 may be comprised ofan electric resistive wire heater helically wound around a ceramicrod-like core. Heater 24 may be tailored such that heater 24 has avarying amount of power, or different amounts of power axially alongheater 24. For example, electric resistive wire may be wound to resultin tighter or looser coils on ceramic core to increase or decrease theamount of coils, and thus the power density along heater 24. Heater 24may have more tightly wound coils at an end of heater 24 adjacent firstend 18 of probe head 12 to deliver a greater amount of heat to the tip.Alternatively, heater 24 may be uniform such that the power density ofheater 24 is uniform axially along heater 24.

Exterior surface 26 of body 22 is an outer surface of body 22. Exteriorsurface 26 of body 22 is the outer surface of probe head 12. As such,external airflow contacts exterior surface 26. Body 22 has inlets 28A,28B, 28C, and 28D near first end 18 of probe head 12. Inlets 28A, 28B,28C, and 28D are openings in body 22. In this embodiment, body 22 hasfour inlets 28A, 28B, 28C, and 28D. In alternate embodiments, body 22has any suitable number of inlets 28. Each inlet 28A, 28B, 28C, 28D isconnected to a respective air passageway 30A, 30B, 30C, and 30D. Assuch, body 22 has four air passageways 30A, 30B, 30C, and 30D. Airpassageways 30A, 30B, 30C, and 30D extend from respective inlets 28A,28B, 28C, and 28D to second end 20 of probe head 12. Air passageways30A, 30B, 30C, and 30D surround heater 24 such that air passageways 30A,30B, 30C, and 30D are between heater 24 and exterior surface 26 of body22. Air passageways 30A, 30B, 30C, and 30D extend in substantiallystraight lines and twist up to 90 degrees around water dams 32A and 32B.As such, air passageways 30A, 30B, 30C, and 30D may have an undulatinggeometry from first end 18 to second end 20 such that air passageways30A, 30B, 30C, and 30D are redirected around water dams 32A and 32B.Water dams 32A and 32B are positioned in lines of sight of inlets 28A,28B, 28C, and 28D. Water dams 32A extend radially. In this embodiment,body 22 has two water dams 32A and 32B spaced axially from each other.In alternate embodiments, body 22 may have any number of water dams 32Aand 32B.

Heater bore 34 is a cylindrical opening, or well, extending through acenter of body 22. Heater bore 34 is positioned between first end 18 andsecond end 20. Heater bore 34 is shaped to accept rod heater 24. In thisembodiment, body 22 has a single heater bore 34 for a single heater 34.In alternate embodiments, body 22 may have a plurality of heater bores34 to accommodate a plurality of heaters 34. Heater bore 34 has annularinterior surface 36 that contacts heater 24. Specifically, heater 24 isslid into heater bore 34 such that heater 24 is in contact with interiorsurface 36 of heater bore 34.

Heater 24 connects to heater circuitry (not shown) at second end 20 ofprobe head 12, the circuitry going down strut 14 (shown in FIG. 1 ) toconnect to and get power from internal components of air data probe 10.Heater 24 can have different amounts of power along rod heater 24 todistribute more heat or less heat depending on the needs of probe head12, or power can be uniform along heater 24 to further simplifymanufacturing of heater 24.

Thermal resistance of body 22 varies, particularly from heater 24 toexterior surface 26, from first end 18 to second end 20 of probe head 12due to different amounts of material between heater 24 and exteriorsurface 26 moving axially from first end 18 to second end 20 of probehead 12. For example, air passageways 30A, 30B, 30C, and 30D canincrease or decrease in diameter to increase or decrease the amount ofmaterial between heater bore 34 and exterior surface 26, varying thethermal resistance of probe head 12 by having more or less metal tocarry heat radially outward from heater 24. Less metal in probe head 12moving from first end 18 to second end 20 reduces the thermal resistanceand results in less heat conduction from heater 24 to exterior surface26 of probe head 12 moving from first end 18 to second end 20. As such,probe head 12 is conducting less heat near second end 20 and divertingmore heat toward first end 18, or tip, of probe head 12.

Air passageways 30A, 30B, 30C, and 30D are not fully linear and twist,or undulate, around heater bore 34 and water dams 32A and 32B to resultin a line-of-sight deflection from first end 18. An absence of astraight path from inlets 28A, 28B, 28C, and 28D, at first end 18, tosecond end 20 of probe head 12, as shown in FIG. 2F, assists in managingwater that could get into probe head 12. Water dams 32A and 32Bredirect, or knock down, water particles in the airflow moving throughair passageways 30A, 30B, 30C, and 30D. Water dams 32A and 32B block iceand water particles in exterior airflow and prevent ice and waterparticles from having a direct route down air passageways 30A, 30B, 30C,and 30D and through probe head 12.

Traditional air data probes have a wire heater brazed to a body of aprobe head. Other components, such as water dams, may also be positionedwithin and brazed onto traditional probe heads. As such, probe heads oftraditional air data probes have complex heaters incorporated intomulti-piece assemblies.

Additive manufacturing allows for more complex internal geometry,including air passageways 30A, 30B, 30C, and 30D, water dams 32A and32B, and heater bore 34, of probe head 12, which is needed for optimalfunctionality of air data probe 10. Because body 22 is a single unitarypiece, air passageways 30A, 30B, 30C, and 30D, water dams 32A and 32B,and heater bore 34 are uniform in size, shape, and position among probeheads 12 to ensure optimal fit and performance as well as repeatability.For example, heater bore 34, water dams 32A and 32B, and air passageways30A, 30B, 30C, and 30D are combined with rod heater 24 and body 22ensures the best fit between heater 24 and body 22. Additivelymanufactured body 22 of probe head 12 allows for easier and moreeffective use of rod-shaped heater 24.

Rod heater 24 is simpler than a traditional complex heater brazed into aprobe head. Because the power density of rod heater 24 can changeaxially along heater 24, heater 24 still maintains the ability to tailorheat distribution within probe head 12 by enhancing conduction to theportions of probe head 12 that need heat via varied power density ofheater 24. Rod heater 24 can be a standardized heater among probe heads12. Heater 24 is also easier to manufacture and simplifies the assemblyprocess of probe head 12.

The geometry of air passageways 30A, 30B, 30C, and 30D allows airpassageways 30A, 30B, 30C, and 30D to twist around water dams 32A and32B positioned in their direct path from first end 18. Water dams 32Aand 32B prevent ice and water particles from external airflow frommoving through probe head 12 and decreasing functionality of air dataprobe 10.

Utilizing additive manufacturing to create more complex internalgeometry of body 22, which has a complex one-piece shape that includesair passageways 30A, 30B, 30C, and 30D, water dams 32A and 32B, andheater bore 34, and integrating a simpler form of a heater via rodheater 24 achieves the internal shapes and passages needed for optimalfunctionality of probe head 12 while enhancing heat conduction andsimplifying manufacturing and assembly of probe head 12.

FIG. 3A is a partial perspective view of probe head 112. FIG. 3B is acut away view of probe head 112. FIG. 3C is a cross-sectional view ofprobe head 112. FIG. 3D is a cross-sectional view of probe head 112.FIG. 3E is an end view of probe head 112. FIGS. 3A, 3B, 3C, 3D, and 3Ewill be discussed together. Probe head 112 includes first end 118,second end 120, body 122, and heaters 124A and 124B. Body 122 includesexterior surface 126, inlet 128, air passageway 130, water dam 132, andheater bores 134A and 134B. Heater bore 134A includes interior surface136A. Heater bore 134B includes interior surface 136B.

Probe head 112 has first end 118 making up the tip of probe head 112.Second end 120 is opposite first end 118. Second end 120 of probe head112 is connected to strut 14 (shown in FIG. 1 ). Body 122 of probe head112 extends from first end 118 to second end 120. Body 122 is a unitary,or single-piece, structure. Body 122 is additively manufactured and madeof nickel or any other suitable material. Heaters 124A and 124B arepositioned within body 122. In this embodiment, probe head 112 has twoside-by-side heaters 124A and 124B. Heaters 124A and 124B are spacedradially from each other. As such, heaters 124A and 124B are positionedadjacent exterior surface 126 of body 126. Heaters 124A and 124B are rodheaters, which includes both rod and rod-like structures. Each heater124A, 124B may be comprised of an electric resistive wire heaterhelically wound around a ceramic rod-like core. Each heater 124A, 124Bmay be tailored such that heater 124A, 124B has different amounts ofpower along heater 124A, 124B. For example, electric resistive wire maybe wound to result in tighter or looser coils on ceramic core toincrease or decrease the amount of coils, and thus the power densityalong heater 124A, 124B. Heater 124A, 124B may have more tightly woundcoils at an end of heater 124A, 124B adjacent first end 118 of probehead 112 to deliver a greater amount of heat to the tip. Alternatively,heater 124A, 124B may be uniform such that the power density of heater124A, 124B is uniform along heater 124A, 124B.

Exterior surface 126 of body 122 is an outer surface of body 122.Exterior surface 126 of body 122 is the outer surface of probe head 112.As such, external airflow contacts exterior surface 126. Body 122 hasinlet 128 near first end 118 of probe head 112. Inlet 128A is an openingin body 122. In this embodiment, body 122 has a single inlet 128A. Inlet128 is connected to air passageway 130. As such, body 122 has a singleair passageway 130. Air passageway 130 extends from inlets 128 to secondend 120 of probe head 112. Air passageway 130 extends through a center,or down the middle, of body 122. A majority of air passageway 130extends between heaters 124A and 124B such that heaters 124A and 124Bare between a majority of air passageway 130 and exterior surface 126 ofbody 122. Air passageway 130 extends in a substantially straight lineand twists up to 90 degrees around water dam 132. As such, airpassageway 130 may have an undulating geometry from first end 118 tosecond end 120 such that air passageway 130 is redirected around waterdam 132. Water dam 132 is positioned in the line of sight of inlet 128.Water dam 132 extends radially. In this embodiment, body 122 has asingle water dam 132.

Each heater 124A, 124B is positioned within a heater bore 134A, 134B.Heater bores 134A and 134B are cylindrical openings, or wells, extendingalong body 122 adjacent exterior surface 126. Heater bores 134A and 134Bare positioned between first end 118 and second end 120. Heater bores134A and 134B are not aligned. Rather, heater bores 134A and 134B areuniformly offset from exterior surface 126 of probe head 112, which isslightly tapered. Each heater bore 134A, 134B is shaped to accept arespective rod heater 124A, 124B. In this embodiment, body 122 has twoheater bores 134A and 134B to accommodate two heaters 134A and 134B. Inalternate embodiments, probe head 112 may have one or more than twoheaters 124A and 124B, each heater 124A, 124B positioned within arespective heater bore 134A, 134B. Each heater bore 134A, 134B hasannular interior surface 136A, 136B that contacts respective heater124A, 124B. Each heater 124A, 124B is slid into a respective heater bore134A, 134B such that each heater 124A, 124B is in contact with aninterior surface of heater bore 134A, 134B.

Heaters 124A and 124B connect to heater circuitry (not shown) at secondend 120 of probe head 112, the circuitry going down strut 14 (shown inFIG. 1 ) to connect to and get power from internal components of airdata probe 10. Heaters 124A and 124B can have different amounts of poweralong rod heaters 124A and 124B to distribute more heat or less heatdepending on the needs of probe head 112, or power can be uniform alongheaters 124A and 124B to further simplify manufacturing of heaters 124Aand 124B.

Thermal resistance of body 122 varies, particularly from each heater124A, 124B to exterior surface 126, from first end 118 to second end 120of probe head 112 due to different amounts of material between eachheater 124A, 124B and exterior surface 126 moving axially from first end118 to second end 120 of probe head 112. The thermal resistance of probehead 112 can be varied by having more or less metal to carry heatradially outward from heaters 124A and 124B. Less metal in probe head112 moving from first end 118 to second end 120 reduces the thermalresistance and results in less heat conduction from heaters 124A and124B to exterior surface 126 of probe head 112 moving from first end 118to second end 120. As such, probe head 112 may conduct less heat nearsecond end 120 and divert more heat toward first end 118, or tip, ofprobe head 112.

Air passageway 130 is not fully linear and twists, or undulates, aroundheater bores 134A and 134B and water dam 132 to result in aline-of-sight deflection from first end 118. An absence of a straightpath from inlet 128 at first end 118 to second end 120 of probe head112, as shown in FIG. 3E, assists in managing water that could get intoprobe head 112. Water dam 132 redirects, or knocks down, water particlesin the airflow moving through air passageway 130. Water dam 132 blocksice and water particles in exterior airflow and prevents ice and waterparticles from having a direct route down air passageway 130 and throughprobe head 112.

Additive manufacturing allows for more complex internal geometry,including air passageway 130, water dam 132, and heater bores 134A and134B, of probe head 112, which is needed for optimal functionality ofair data probe 10. For example, probe head 112 is able to have twoheater bores 134A and 134B, positioned exactly where needed, as well asthe required internal geometry of air passageway 130 and water dam 132that probe head 112 requires in order to function properly due toadditively manufacturing probe head 112. Because body 122 is a singleunitary piece, air passageway 130, water dam 132, and heater bores 134Aand 134B are uniform in size, shape, and position among probe heads 112to ensure optimal fit and performance as well as repeatability. Forexample, heater bores 134A and 134B, water dam 132, and air passageway130 are combined with rod heaters 124A and 124B and body 122 ensures thebest fit between heaters 124A and 124A and 124B and body 122. Additivelymanufactured body 122 of probe head 112 allows for easier and moreeffective use of rod-shaped heaters 124A and 124B.

Additive manufacturing allows for two heaters 124A and 124B, positionedside-by-side, to increase the heating ability of probe head 112 comparedto probe head 12 that has a single heater 24, as shown in FIGS. 2A-2F,when more heat is required. Probe head 112 can respond to increased heatdemands. Heater bores 134A and 134B are additively manufactured exactlywhere heat is needed such that heaters 124A and 124B provide enough heatwithin probe head 112. Further, water dam 132 and air passageway 130 areadditively manufactured and shaped differently to accommodate multipleheater bores 134A and 134B. The geometry of air passageway 130 allowsair passageway 130 to twist around water dams 132 positioned in itsdirect path from first end 118. Water dam 132 prevents ice and waterparticles from external airflow from moving through probe head 112 anddecreasing functionality of air data probe 110.

Rod heaters 124A and 124B are simpler than a traditional complex heaterbrazed into a probe head. Because the power density of rod heaters 124Aand 124B can change axially along heaters 124A and 124B, heaters 124Aand 124B still maintain the ability to tailor heat distribution withinprobe head 112 by enhancing conduction to the portions of probe head 112that need heat via varied power density of heaters 124A and 124B. Rodheaters 124A and 124B can be standardized heaters among probe heads 112.Heaters 124A and 124B are also easier to manufacture and simplify theassembly process of probe head 112.

Utilizing additive manufacturing to create more complex internalgeometry of body 122, which has a complex one-piece shape that includesair passageway 130, water dams 132, and heater bores 134A and 134B, andintegrating a simpler form of heaters via rod heaters 124A and 124Bachieves the internal shapes and passages needed for optimalfunctionality of probe head 112 while enhancing heat conduction andsimplifying manufacturing and assembly of probe head 112.

FIG. 4A is a perspective top view of air data probe 210 showing enhancedconduction areas 238 of probe head 212. FIG. 4B is a partial perspectivefront view of probe head 212 showing enhanced conduction areas 238A,238B, 238C, and 238D. FIG. 4C is a partial perspective front view ofprobe head 212 with part of body 222 of probe head 212 removed to showenhanced conduction areas 238A, 238B, 238C, and 238D. FIG. 4D is across-sectional view of probe head 212 taken along line D-D of FIG. 4A.FIG. 4E is a cross-sectional view of probe head 212 taken along line E-Eof FIG. 4A. FIGS. 4A, 4B, 4C, 4D, and 4E will be discussed together. Airdata probe 210 includes probe head 212, strut 214, and mounting flange216. Probe head 212 includes first end 218, second end 220, body 222,and heater 224. Body 222 includes exterior surface 226, inlets 228A,228B, 228C, and 228D, air passageways 230A, 230B, 230C, and 230D, waterdams 232A and 232B, heater bore 234 (including interior surface 236),and enhanced conduction areas 238A, 238B, 238C, and 238D.

Probe head 212 has first end 218 making up the tip of probe head 212.Second end 220 is opposite first end 218. Second end 220 of probe head212 is connected to strut 214. Body 222 of probe head 212 extends fromfirst end 218 to second end 220. Body 222 may be a unitary, orsingle-piece, structure. Body 222 is additively manufactured and made ofnickel or any other suitable material. Heater 224 is positioned withinbody 222. In this embodiment, a single heater 224 extends through acenter, or down the middle, of body 222. Heater 224 is a rod heater,which includes both rod and rod-like structures. Heater 224 may becomprised of an electric resistive wire heater helically wound around aceramic rod-like core. Heater 224 may be tailored such that heater 224has different amounts of power along heater 224. For example, electricresistive wire may be wound to result in tighter or looser coils onceramic core to increase or decrease the amount of coils, and thus thepower density along heater 224. Heater 224 may have more tightly woundcoils at an end of heater 224 adjacent first end 218 of probe head 212to deliver a greater amount of heat to the tip. Alternatively, heater224 may be uniform such that the power density of heater 224 is uniformalong heater 224.

Exterior surface 226 of body 222 is an outer surface of body 222.Exterior surface 226 of body 222 is the outer surface of probe head 212.As such, external airflow contacts exterior surface 226. Body 222 hasinlets 228A, 228B, 228C, and 228D near first end 218 of probe head 212.Inlets 228A, 228B, 228C, and 228D are openings in body 222. In thisembodiment, body 222 has four inlets 228A, 228B, 228C, and 228D. Inalternate embodiments, body 222 has any suitable number of inlets 228.Each inlet 228A, 228B, 2228C, 28D is connected to a respective airpassageway 230A, 230B, 230C, and 230D. As such, body 222 has four airpassageways 230A, 230B, 230C, and 230D. Air passageways 230A, 230B,230C, and 230D extend from respective inlets 228A, 228B, 228C, and 228Dto second end 220 of probe head 212. Air passageways 230A, 230B, 230C,and 230D surround heater 224 such that air passageways 230A, 230B, 230C,and 230D are between heater 224 and exterior surface 226 of body 222.Air passageways 230A, 230B, 230C, and 230D extend in substantiallystraight lines and twist up to 90 degrees around water dams 232A and232B. As such, air passageways 230A, 230B, 230C, and 230D may have anundulating geometry from first end 218 to second end 220 such that airpassageways 230A, 230B, 230C, and 230D are redirected around water dams232A and 232B. Water dams 232A and 232B are positioned in lines of sightof inlets 228A, 228B, 228C, and 228D. Water dams 232A extend radially.In this embodiment, body 222 has two water dams 232A and 232B spacedaxially from each other. In alternate embodiments, body 222 may have anynumber of water dams 232A and 232B.

Heater bore 234 is a cylindrical opening, or well, extending through acenter of body 222. Heater bore 234 is positioned between first end 218and second end 220. Heater bore 234 is shaped to accept rod heater 224.In this embodiment, body 222 has a single heater bore 234 for a singleheater 234. In alternate embodiments, body 222 may have a plurality ofheater bores 234 to accommodate a plurality of heaters 234. Heater bore234 has annular interior surface 236 that contacts heater 224.Specifically, heater 224 is slid into heater bore 234 such that heater224 is in contact with interior surface 236 of heater bore 234. Exteriorsurface 226, inlets 228A, 228B, 228C, and 228D, air passageways 230A,230B, 230C, and 230D, water dams 232A and 232B, and heater bore 234 areall unitary to body 222, forming a single-piece structure.

Enhanced conduction areas 238A, 238B, 238C, and 238D are between heaterbore 234 and exterior surface 226 of probe head 212. Enhanced conductionareas 238A, 238B, 238C, and 238D are areas of enhanced thermalconduction. Enhanced conduction areas 238A, 238B, 238C, and 238D fillspaces in body 222 between internal components including air passageways230A, 230B, 230C, and 230D, water dams 232A and 232B, and heater bore234. Enhanced conduction areas 238A, 238B, 238C, and 238D are as largeas possible, filling areas between internal components of body 222 whilemaintaining a uniform minimum wall thickness (such as about 25thousandths of an inch) of, or offset from, internal components andexterior surface 226. Enhanced conduction areas 238A, 238B, 238C, and238D are comprised of material having a higher thermal conductivity thanthe material forming the rest of body 222. For example, enhancedconduction areas 238A, 238B, 238C, and 238D may be a silver-copperalloy, which has heat conductivity about 3.5 times that of nickel.

Enhanced conduction areas 238A, 238B, 238C, and 238D are created byforming one or more cavities, or pockets, in body 222 during additivemanufacturing of body 222 and filling the cavities with material havinga higher conductivity than the material forming the rest of body 222.For example, the cavities may be filled with a silver-copper alloy. Thecavities may be filled via multi-material additive manufacturing, via atwo-step process by melting in the higher conductivity material in avacuum furnace process, or via any other suitable process. As such,enhanced conduction areas 238A, 238B, 238C, and 238D may also be unitaryto body 222. The higher conductivity material may be in the form of apowder, a wire (such as a pelletized wire), or in any other suitableform prior to filling cavities within body 222.

Heater 224 connects to heater circuitry (not shown) at second end 220 ofprobe head 212, the circuitry going down strut 214 to connect to and getpower from internal components of air data probe 210. Heater 224 canhave different amounts of power along rod heater 224 to distribute moreheat or less heat depending on the needs of probe head 212, or power canbe uniform along heater 224 to further simplify manufacturing of heater224.

Thermal resistance of body 222 varies, particularly from heater 224 toexterior surface 226, from first end 218 to second end 220 of probe head212 due to different amounts of material between heater 224 and exteriorsurface 226 moving axially from first end 218 to second end 220 of probehead 212. For example, air passageways 230A, 230B, 230C, and 230D canincrease or decrease in diameter to increase or decrease the amount ofmaterial between heater bore 234 and exterior surface 226, varying thethermal resistance of probe head 212 by having more or less metal tocarry heat radially outward from heater 224. Less metal in probe head212 moving from first end 218 to second end 220 reduces the thermalresistance and results in less heat conduction from heater 224 toexterior surface 226 of probe head 212 moving from first end 218 tosecond end 220. As such, probe head 212 is conducting less heat nearsecond end 220 and diverting more heat toward first end 218, or tip, ofprobe head 212. Enhanced conduction areas 238A, 238B, 238C, and 238Dmaximize heat conduction by filling the space between internalcomponents of body 222 while maintaining a uniform offset from, or wallthickness of, internal components and exterior surface 226 needed forthe functionality of probe head 212. As such, enhanced conduction areas238A, 238B, 238C, and 238D may also increase or decrease in size movingaxially from first end 218 to second end 220 of probe head 212. Forexample, enhanced conduction areas 238A, 238B, 238C, and 238D may belarger near tip, or first end 218, of probe head 212, resulting inhigher thermal conductivity and greater heat conduction to first end218.

Air passageways 230A, 230B, 230C, and 230D are not fully linear andtwist, or undulate, around heater bore 234 and water dams 232A and 232Bto result in a line-of-sight deflection from first end 218. An absenceof a straight path from inlets 228A, 228B, 228C, and 228D, at first end218, to second end 220 of probe head 212, as shown in FIG. 4D, assistsin managing water that could get into probe head 212. Water dams 232Aand 232B redirect, or knock down, water particles in the airflow movingthrough air passageways 230A, 230B, 230C, and 230D. Water dams 232A and232B block ice and water particles in exterior airflow and prevent iceand water particles from having a direct route down air passageways230A, 230B, 230C, and 230D and through probe head 212.

Traditional air data probes have a wire heater brazed to a body of aprobe head. Other components, such as water dams, may also be positionedwithin and brazed onto traditional probe heads. As such, probe heads oftraditional air data probes have complex heaters incorporated intomulti-piece assemblies. Additionally, probe head bodies are typicallyformed of a single material.

Additive manufacturing allows for more complex internal geometry,including air passageways 230A, 230B, 230C, and 230D, water dams 232Aand 232B, heater bore 234, and enhanced conduction areas 238A, 238B,238C, and 238D of probe head 212, which contribute to optimalfunctionality of air data probe 210. Because exterior surface 226,inlets 228A, 228B, 228C, and 228D, air passageways 230A, 230B, 230C, and230D, water dams 232A and 232B, heater bore 234 of body 222 form asingle unitary piece, air passageways 230A, 230B, 230C, and 230D, waterdams 232A and 232B, and heater bore 234 are uniform in size, shape, andposition among probe heads 212 to ensure optimal fit and performance aswell as repeatability. For example, heater bore 234, water dams 232A and232B, and air passageways 230A, 230B, 230C, and 230D are combined withrod heater 224 and body 222 ensures the best fit between heater 224 andbody 222. Further, enhanced conduction areas 238A, 238B, 238C, and 238Dformed via multi-material additive manufacturing are uniform among probeheads 212, also ensuring optimal performance and repeatability.Additively manufactured body 222 of probe head 212 allows for easier andmore effective use of rod-shaped heater 224 and enhanced conductionareas 238A, 238B, 238C, and 238D.

Rod heater 224 is simpler than a traditional complex heater brazed intoa probe head. Because the power density of rod heater 224 can changeaxially along heater 224, heater 224 still maintains the ability totailor heat distribution within probe head 212 by enhancing conductionto the portions of probe head 212 that need heat via varied powerdensity of heater 224. Rod heater 224 can be a standardized heater amongprobe heads 212. Heater 224 is also easier to manufacture and simplifiesthe assembly process of probe head 212. Enhanced conduction areas 238A,238B, 238C, and 238D are also integrated into body 222 to further tailorheat distribution within probe head 212. Enhanced conduction areas 238A,238B, 238C, and 238D allow for more heat conduction toward first end218, or tip, of probe head 212 while maintaining a simple manufactureand assembly of probe head 212.

The geometry of air passageways 230A, 230B, 230C, and 230D allows airpassageways 230A, 230B, 230C, and 230D to twist around water dams 232Aand 232B positioned in their direct path from first end 218. Water dams232A and 232B prevent ice and water particles from external airflow frommoving through probe head 212 and decreasing functionality of air dataprobe 210.

Utilizing additive manufacturing to create more complex internalgeometry of body 222, which has a complex one-piece shape that includesair passageways 230A, 230B, 230C, and 230D, water dams 232A and 232B,heater bore 234, and enhanced conduction areas 238A, 238B, 238C, and238D and integrating a simpler form of a heater via rod heater 224achieves the internal shapes and passages needed for optimalfunctionality of probe head 212 while enhancing heat conduction andsimplifying manufacturing and assembly of probe head 212.

FIG. 5A is a perspective top view of air data probe 310 showing enhancedconduction area 338 of probe head 312. FIG. 5B is a partial perspectivefront view of probe head 312 showing enhanced conduction area 338. FIG.5C is a partial perspective front view of probe head 312 with part ofbody 322 of probe head 312 removed to show enhanced conduction area 338.FIG. 5D is a cross-sectional view of probe head 312 taken along line D-Dof FIG. 5A. FIG. 5E is a cross-sectional view of probe head 312 takenalong line E-E of FIG. 5A. FIGS. 5A, 5B, 5C, 5D, and 5E will bediscussed together. Air data probe 310 includes probe head 312, strut314, and mounting flange 316. Probe head 312 includes first end 318,second end 320, body 322, and heaters 324A and 324B. Body 326 includesexterior surface 326, inlet 328, air passageway 330, water dam 332, andheater bores 334A and 334B (including interior surface 336A and interiorsurface 336B, respectively) and enhanced conduction area 338.

Probe head 312 has first end 318 making up the tip of probe head 312.Second end 320 is opposite first end 318. Second end 320 of probe head312 is connected to strut 314. Body 322 of probe head 312 extends fromfirst end 318 to second end 320. Body 322 may be a unitary, orsingle-piece, structure. Body 322 is additively manufactured and made ofnickel or any other suitable material. Heaters 324A and 324B arepositioned within body 322. In this embodiment, probe head 312 has twoside-by-side heaters 324A and 324B. Heaters 324A and 324B are spacedradially from each other. As such, heaters 324A and 324B are positionedadjacent exterior surface 326 of body 326. Heaters 324A and 324B are rodheaters, which includes both rod and rod-like structures. Each heater324A, 324B may be comprised of an electric resistive wire heaterhelically wound around a ceramic rod-like core. Each heater 324A, 324Bmay be tailored such that heater 324A, 324B has different amounts ofpower along heater 324A, 324B. For example, electric resistive wire maybe wound to result in tighter or looser coils on ceramic core toincrease or decrease the amount of coils, and thus the power densityalong heater 324A, 324B. Heater 324A, 324B may have more tightly woundcoils at an end of heater 324A, 324B adjacent first end 318 of probehead 312 to deliver a greater amount of heat to the tip. Alternatively,heater 324A, 324B may be uniform such that the power density of heater324A, 324B is uniform along heater 324A, 324B.

Exterior surface 326 of body 322 is an outer surface of body 322.Exterior surface 326 of body 322 is the outer surface of probe head 312.As such, external airflow contacts exterior surface 326. Body 322 hasinlet 328 near first end 318 of probe head 312. Inlet 328A is an openingin body 322. In this embodiment, body 322 has a single inlet 328A. Inlet328 is connected to air passageway 330. As such, body 322 has a singleair passageway 330. Air passageway 330 extends from inlets 328 to secondend 320 of probe head 312. Air passageway 330 extends through a center,or down the middle, of body 322. A majority of air passageway 330extends between heaters 324A and 324B such that heaters 324A and 324Bare between a majority of air passageway 330 and exterior surface 326 ofbody 322. Air passageway 330 extends in a substantially straight lineand twists up to 90 degrees around water dam 332. As such, airpassageway 330 may have an undulating geometry from first end 318 tosecond end 320 such that air passageway 330 is redirected around waterdam 332. Water dam 332 is positioned in the line of sight of inlet 328.Water dam 332 extends radially. In this embodiment, body 322 has asingle water dam 332.

Each heater 324A, 324B is positioned within a heater bore 334A, 334B.Heater bores 334A and 334B are cylindrical openings, or wells, extendingalong body 322 adjacent exterior surface 326. Heater bores 334A and 334Bare positioned between first end 318 and second end 320. Heater bores334A and 334B are not aligned. Rather, heater bores 334A and 334B areoffset from exterior surface 326 of probe head 312, which is slightlytapered. Each heater bore 334A, 334B is shaped to accept a respectiverod heater 324A, 324B. In this embodiment, body 322 has two heater bores334A and 334B to accommodate two heaters 334A and 334B. In alternateembodiments, probe head 312 may have one or more than two heaters 324Aand 324B, each heater 324A, 324B positioned within a respective heaterbore 334A, 334B. Each heater bore 334A, 334B has annular interiorsurface 336A, 336B that contacts respective heater 324A, 324B. Eachheater 324A, 324B is slid into a respective heater bore 334A, 334B suchthat each heater 324A, 324B is in contact with an interior surface ofheater bore 334A, 334B. Exterior surface 326, inlets 328, air passageway330, water dam 332, and heater bores 334A and 334B are all unitary tobody 322, forming a single-piece structure.

Enhanced conduction area 338 is between heater bores 334A and 334 andexterior surface 326 of probe head 312. Enhanced conduction area 338 isan area of enhanced thermal conduction. Enhanced conduction area 338surrounds inlet 328, air passageway 330, and water dam 232. Enhancedconduction area 338 fills space in body 322 between internal components.Enhanced conduction area 338 is as large as possible in a portion ofbody 322 adjacent first end 318, filling areas between internalcomponents of body 322 while maintaining a uniform minimum wallthickness (such as about 25 thousandths of an inch) of, or offset from,internal components and exterior surface 326. In this embodiment,enhanced conduction area 338 does not extend to second end 320. Enhancedconduction area 338 is comprised of material having a higher thermalconductivity than the material forming the rest of body 322. Forexample, enhanced conduction area 338 may be a silver-copper alloy,which has a heat conductivity about 3.5 times that of nickel.

Enhanced conduction area 338 is created by forming a cavity, or pocket,in body 322 during additive manufacturing of body 322 and filling thecavity with material having a higher conductivity than the materialforming the rest of body 322. For example, the cavity may be filled witha silver-copper alloy. The cavities may be filled via multi-materialadditive manufacturing, via a two-step process by melting in the higherconductivity material in a vacuum furnace process, or via any othersuitable process. As such, enhanced conduction area 338 may also beunitary to body 322. The higher conductivity material may be in the formof a powder, a wire (such as a pelletized wire), or in any othersuitable form prior to filling cavities within body 322.

Heaters 324A and 324B connect to heater circuitry (not shown) at secondend 320 of probe head 312, the circuitry going down strut 314 to connectto and get power from internal components of air data probe 310. Heaters324A and 324B can have different amounts of power along rod heaters 324Aand 324B to distribute more heat or less heat depending on the needs ofprobe head 312, or power can be uniform along heaters 324A and 324B tofurther simplify manufacturing of heaters 324A and 324B.

Thermal resistance of body 322 varies, particularly from each heater324A, 324B to exterior surface 326, from first end 318 to second end 320of probe head 312 due to different amounts of material between eachheater 324A, 324B and exterior surface 326 moving axially from first end318 to second end 320 of probe head 312. The thermal resistance of probehead 312 can be varied by having more or less metal to carry heatradially outward from heaters 324A and 324B. Less metal in probe head312 moving from first end 318 to second end 320 reduces the thermalresistance and results in less heat conduction from heaters 324A and324B to exterior surface 326 of probe head 312 moving from first end 318to second end 320. As such, probe head 312 may conduct less heat nearsecond end 320 and divert more heat toward first end 318, or tip, ofprobe head 312. Enhanced conduction area 238 maximizes heat conduction,particularly near first end 318, by filling the space between internalcomponents of body 322 in a front portion of body 322 near first end 318while maintaining a uniform offset from, or wall thickness of, internalcomponents and exterior surface 326 needed for the functionality ofprobe head 312. As such, enhanced conduction area 338 may also increaseor decrease in size moving axially away from first end 318 toward secondend 320 of probe head 312. For example, enhanced conduction area 338 maybe larger near tip, or first end 318, of probe head 312, resulting inhigher thermal conductivity and greater heat conduction to first end318. Enhanced conduction area 338 is also fully annular closer to, oradjacent, first end 318, resulting in greater heat conduction to tip, orfirst end 318.

Air passageway 330 is not fully linear and twists, or undulates, aroundheater bores 334A and 334B and water dam 332 to result in aline-of-sight deflection from first end 318. An absence of a straightpath from inlet 328 at first end 318 to second end 320 of probe head312, as shown in FIG. 5D, assists in managing water that could get intoprobe head 312. Water dam 332 redirects, or knocks down, water particlesin the airflow moving through air passageway 330. Water dam 332 blocksice and water particles in exterior airflow and prevents ice and waterparticles from having a direct route down air passageway 330 and throughprobe head 312.

Additive manufacturing allows for more complex internal geometry,including air passageway 330, water dam 332, heater bores 334A and 334B,and enhanced conduction area 338 of probe head 312, which contribute tooptimal functionality of air data probe 310. For example, probe head 312is able to have two heater bores 334A and 334B, positioned exactly whereneeded, and enhanced conduction area 238 as well as the requiredinternal geometry of air passageway 330 and water dam 332 that probehead 312 requires in order to function properly due to additivelymanufacturing probe head 312. Because exterior surface 326, inlets 328,air passageway 330, water dam 332, heater bores 334A and 334B of body322 form a single unitary piece, air passageway 330, water dam 332, andheater bores 334A and 334B are uniform in size, shape, and positionamong probe heads 312 to ensure optimal fit and performance as well asrepeatability. For example, heater bores 334A and 334B, water dam 332,and air passageway 330 are combined with rod heaters 324A and 324B andbody 322 ensures the best fit between heaters 324A and 324A and 324B andbody 322. Further, enhanced conduction area 238 formed viamulti-material additive manufacturing is uniform among probe heads 312,also ensuring optimal performance and repeatability. Additivelymanufactured body 322 of probe head 312 allows for easier and moreeffective use of rod-shaped heaters 324A and 324B and enhancedconduction area 338.

Additive manufacturing allows for two heaters 324A and 324B, positionedside-by-side, to increase the heating ability of probe head 312 comparedto probe head 12 that has a single heater 24, as shown in FIGS. 2A-2F,when more heat is required. Probe head 312 can respond to increased heatdemands. Heater bores 334A and 334B are additively manufactured exactlywhere heat is needed such that heaters 324A and 324B provide enough heatwithin probe head 312. Further, water dam 332, air passageway 330, andenhanced conduction area 338 are additively manufactured and shapeddifferently to accommodate multiple heater bores 334A and 334B. Thegeometry of air passageway 330 allows air passageway 330 to twist aroundwater dams 332 positioned in its direct path from first end 318. Waterdam 332 prevents ice and water particles from external airflow frommoving through probe head 312 and decreasing functionality of air dataprobe 310. A forward end of enhanced conduction area 338 is forward ofheaters 324A and 324B in order to provide increased heat distribution tofirst end 318, which is subject to most extreme icing conditions.

Rod heaters 324A and 324B are simpler than a traditional complex heaterbrazed into a probe head. Because the power density of rod heaters 324Aand 324B can change axially along heaters 324A and 324B, heaters 324Aand 324B still maintain the ability to tailor heat distribution withinprobe head 312 by enhancing conduction to the portions of probe head 312that need heat via varied power density of heaters 324A and 324B. Rodheaters 324A and 324B can be standardized heaters among probe heads 312.Heaters 324A and 324B are also easier to manufacture and simplify theassembly process of probe head 312. Enhanced conduction area 238 is alsointegrated into body 322 to further tailor heat distribution withinprobe head 312. Enhanced conduction area 238 allows for more heatconduction toward first end 318, or tip, of probe head 312 whilemaintaining a simple manufacture and assembly of probe head 312.

Utilizing additive manufacturing to create more complex internalgeometry of body 322, which has a complex one-piece shape that includesair passageway 330, water dams 332, heater bores 334A and 334B, andenhanced conduction area 338 and integrating a simpler form of heatersvia rod heaters 324A and 324B achieves the internal shapes and passagesneeded for optimal functionality of probe head 312 while enhancing heatconduction and simplifying manufacturing and assembly of probe head 312.

Discussion of Possible Embodiments

The following are non-exclusive descriptions of possible embodiments ofthe present invention.

A probe head of an air data probe includes a body extending from a firstend to a second end of the probe head, the body comprising: an inletadjacent the first end of the probe head; an air passageway extendingthrough the body from the inlet to a second end of the probe head; awater dam extending radially through the body such that the airpassageway is redirected around the water dam; a heater bore extendingwithin the body; and an enhanced conduction area between heater bore andan exterior surface of the probe head; wherein the inlet, the airpassageway, the water dam, and the heater bore are all unitary to thebody; and a rod heater positioned within the heater bore.

The probe head of the preceding paragraph can optionally include,additionally and/or alternatively, any one or more of the followingfeatures, configurations and/or additional components:

The enhanced conduction area is comprised of a material having a higherthermal conductivity than a material forming the inlet, the airpassageway, the water dam, and the heater bore of the body.

The enhanced conduction area is formed by filling a cavity within thebody with a material having a higher conductivity than a materialforming the inlet, the air passageway, the water dam, and the heaterbore of the body.

The material forming the inlet, the air passageway, the water dam, andthe heater bore is nickel.

The material having a higher conductivity than the material forming theinlet, the air passageway, the water dam, and the heater bore of thebody is a silver-copper alloy.

The cavity within the body is filled via multi-material additivemanufacturing.

The cavity within the body is filled by melting the material having ahigher conductivity into the cavity after the body is additivelymanufactured.

The body further comprises an exterior surface that is unitary to theinlet, the air passageway, the water dam, and the heater bore of thebody.

The enhanced conduction area is as large as possible while maintaining auniform offset from the air passageway, the water dam, the heater bore,and an exterior surface of the body.

The uniform offset is about 25 thousandths of an inch.

The enhanced conduction area is unitary to the body.

The enhanced conduction area does not extend to the second end of theprobe head.

The enhanced conduction area is fully annular adjacent the first end ofthe probe head.

The body comprises a plurality of enhanced conduction areas.

The enhanced conduction area is larger near the first end of the probehead.

The body includes a plurality of water dams.

The body includes a plurality of air passageways.

A plurality of rod heaters and wherein the body includes a plurality ofheater bores, each rod heater being positioned in a heater bore.

The air passageway undulates around the water dam.

The single rod heater extends through a center of the body.

While the invention has been described with reference to an exemplaryembodiment(s), it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment(s) disclosed, but that theinvention will include all embodiments falling within the scope of theappended claims.

1. A probe head of an air data probe, the probe head comprising: a bodyextending from a first end to a second end of the probe head, the bodycomprising: an inlet adjacent the first end of the probe head; an airpassageway extending through the body from the inlet to a second end ofthe probe head; a water dam extending radially through the body suchthat the air passageway is redirected around the water dam; a heaterbore extending within the body; and an enhanced conduction area betweenheater bore and an exterior surface of the probe head; wherein theinlet, the air passageway, the water dam, and the heater bore are allunitary to the body; and a rod heater positioned within the heater bore.2. The probe head of claim 1, wherein the enhanced conduction area iscomprised of a material having a higher thermal conductivity than amaterial forming the inlet, the air passageway, the water dam, and theheater bore of the body.
 3. The probe head of claim 1, wherein theenhanced conduction area is formed by filling a cavity within the bodywith a material having a higher conductivity than a material forming theinlet, the air passageway, the water dam, and the heater bore of thebody.
 4. The probe head of claim 3, wherein the material forming theinlet, the air passageway, the water dam, and the heater bore is nickel.5. The probe head of claim 3, wherein the material having a higherconductivity than the material forming the inlet, the air passageway,the water dam, and the heater bore of the body is a silver-copper alloy.6. The probe head of claim 3, wherein the cavity within the body isfilled via multi-material additive manufacturing.
 7. The probe head ofclaim 3, wherein the cavity within the body is filled by melting thematerial having a higher conductivity into the cavity after the body isadditively manufactured.
 8. The probe head of claim 1, wherein the bodyfurther comprises an exterior surface that is unitary to the inlet, theair passageway, the water dam, and the heater bore of the body.
 9. Theprobe head of claim 1, wherein the enhanced conduction area is as largeas possible while maintaining a uniform offset from the air passageway,the water dam, the heater bore, and an exterior surface of the body. 10.The probe head of claim 9, wherein the uniform offset is about 25thousandths of an inch.
 11. The probe head of claim 1, wherein theenhanced conduction area is unitary to the body.
 12. The probe head ofclaim 1, wherein the enhanced conduction area does not extend to thesecond end of the probe head.
 13. The probe head of claim 1, wherein theenhanced conduction area is fully annular adjacent the first end of theprobe head.
 14. The probe head of claim 1, wherein the body comprises aplurality of enhanced conduction areas.
 15. The probe head of claim 1,wherein the enhanced conduction area is larger near the first end of theprobe head.
 16. The probe head of claim 1, wherein the body includes aplurality of water dams.
 17. The probe head of claim 16, wherein thebody includes a plurality of air passageways.
 18. The probe head ofclaim 1, further including a plurality of rod heaters and wherein thebody includes a plurality of heater bores, each rod heater beingpositioned in a heater bore.
 19. The probe head of claim 1, wherein theair passageway undulates around the water dam.
 20. The probe head ofclaim 1, wherein the single rod heater extends through a center of thebody.